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DOE OSTI2021

Wind and Structural Loads on Parabolic Trough Solar Collectors at Nevada Solar One

Wind loading is a main contributor to structural design costs of Concentrating Solar Power (CSP) collectors, such as heliostats and parabolic troughs. These structures must resist the mechanical forces generated by turbulent wind. At the same time, the reflector surfaces must exhibit the necessary rigidity to maintain their optimal optical performance in windy conditions. Over two years, NREL conducted comprehensive field measurements of the atmospheric turbulent wind conditions and the resulting structural wind loads on parabolic troughs at the Nevada Solar One (NSO) plant. The measurement set-up included meteorological masts and structural load sensors on four trough rows. Additionally, we commissioned a lidar scanning the horizontal plane over the trough field. This data set catalogs the high-resolution data set characterizing the complex flow field and resulting structural loads on parabolic trough collectors. By providing this first-of-its-kind data set to the CSP community, we aim to enhance the community's understanding of wind-loading experienced by CSP collector structures. This data set will also help design next-generation solar collectors and photovoltaic trackers.

Array↗

NASA NTRS2019

Metallized Plastic Current Collectors

Metallized plastic current collectors are an innovation patented by the Soteria Battery Innovation Group with the promise of isolating active material involved in an internal short by vaporizing and isolating the short from the rest of the cell electrode jellyroll or stack. Partnering with NREL, UCL, Coulometrics, and Soteria, NASA is leading a research effort into demonstrating the merits and understanding the phenomena of this safety innovation using prototype 18650 cylindrical cells vs control cells with standard metal foil current collectors. Cells with and without the plastic collector, with and without the on-demand internal short circuit device, and with polymer or cellulose separators were made. Safety evaluations were done with driving cells into thermal runaway (TR) with thermal and nail penetration triggers while inside our TR calorimeter and with ultra high speed X-ray videography provided at Synchrotrons. Preliminary results suggests that the thermally unstable plastic current collector innovation has great promise for preventing TR or reducing the severity of the TR output.

Li-ion cell↗

NASA NTRS2024

Removing Contamination From Genesis Sapphire Collectors By Polishing

The Array Collectors of the Genesis spacecraft collected bulk solar wind (SW), as well as three subsets of SW (fast, slow, and coronal mass ejection) in a variety of materials. In all cases the SW implant peaked within < 0.2 microns of the surface. So, when the sample return capsule crashed on landing, cleaning the surfaces for analysis became an extremely difficult, but imperative, task. One collector material was “sapphire”, commercial single crystal corundum. Only ~7.7% of the Genesis Array collectors were sapphire (SAP) but a much higher percentage survived the crash. In fact, surviving bulk SW sapphire collectors have an average area ~10x that of their silicon counterparts since SAP is physically tough, and hard (MOHS 9, by definition) as well as is chemically inert. So, SAP is a good candidate for analytical techniques for measuring SW that require clean areas larger than a millimeter; e.g., synchrotron TXRF and INAA. It is also possible to measure SW in SAP using laser ablation and secondary ion mass spectrometry (SIMS) and, recently, more researchers are choosing to analyze sapphire. Thus, removing surface contamination from SAP could enable many research projects. This report extends the task presented in Schmeling et al. ([4]) that used polishing compounds to remove contamination from Genesis sapphire. It focuses on how polishing with their two top candidates (colloidal silica and cerium oxide) affects the SW layer in SAP.

Genesis solar wind↗

DOE OSTI2024

A New Method for Creating Structured High-Performance Current Collectors for Electrochemical Applications

A significant challenge in many electrochemical systems is finding a stable, high-performing current collector material that is mechanically robust, adaptable in form factor, and free of precious metals. Titanium electrodes are robust in many of these regards but exhibit poor charge transfer performance due to self-passivation. Herein, a new materials processing paradigm based on the titanium/titanium nitride (Ti/TiN) system which allows for robust, stable, and low-resistance current collectors of arbitrary form factor is presented. Specifically, a gas-nitriding process for 3D-printed titanium electrodes that results in a 20-fold improvement of charge transfer characteristics relative to the untreated material is outlined. The ability to utilize 3D-structured current collectors with a net 40-fold improvement in performance over nonstructured electrodes is further demonstrated. This novel approach to creating electrochemical current collectors requires minimal laboratory resources and can be widely adapted for a variety of applications, including desalination, electrolysis, energy storage, and basic research. In conclusion, the work described herein provides both a means for accelerating research and opens the door to hierarchical tuneability for enhanced performance.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Stable Anode–Free All–Solid–State Lithium Battery through Tuned Metal Wetting on the Copper Current Collector

A stable anode-free all-solid-state battery (AF-ASSB) with sulfide-based solid-electrolyte (SE) (argyrodite Li 6 PS 5 Cl) is achieved by tuning wetting of lithium metal on “empty” copper current-collector. Lithiophilic 1 µm Li 2 Te is synthesized by exposing the collector to tellurium vapor, followed by in situ Li activation during the first charge. The Li 2 Te significantly reduces the electrodeposition/electrodissolution overpotentials and improves Coulombic efficiency (CE). During continuous electrodeposition experiments using half-cells (1 mA cm –2 ), the accumulated thickness of electrodeposited Li on Li 2 Te–Cu is more than 70 µm, which is the thickness of the Li foil counter-electrode. Full AF-ASSB with NMC811 cathode delivers an initial CE of 83% at 0.2C, with a cycling CE above 99%. Additionally, cryogenic focused ion beam (Cryo-FIB) sectioning demonstrates uniform electrodeposited metal microstructure, with no signs of voids or dendrites at the collector-SE interface. Electrodissolution is uniform and complete, with Li 2 Te remaining structurally stable and adherent. By contrast, an unmodified Cu current-collector promotes inhomogeneous Li electrodeposition/electrodissolution, electrochemically inactive “dead metal,” dendrites that extend into SE, and thick non-uniform solid electrolyte interphase (SEI) interspersed with pores. Density functional theory (DFT) and mesoscale calculations provide complementary insight regarding nucleation-growth behavior. Unlike conventional liquid-electrolyte metal batteries, the role of current collector/support lithiophilicity has not been explored for emerging AF-ASSBs.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Microscopic analysis of copper current collectors and mechanisms of fragmentation under compressive forces

Extensive fragmentation of copper current collectors was observed after spherical indentation on prismatic and large-format pouch Li-ion cells by 3D X-ray computed tomography (XCT). Microscopic analysis including scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM) and x-ray photoelectron microscopy (XPS) was carried out on copper current collectors from used commercial cells and pristine anodes. The copper-graphite cross-section images showed rough interface areas affected by reactions and diffusion in the used cell. Electron probe micro-analyzer (EPMA) element mapping showed the interface area was rich in oxygen and phosphorus. A detectable amount of phosphorus was also uniformly distributed inside the current collector. The same oxygen and phosphorus distributions were confirmed by STEM/EDS analysis. XPS depth profiles on multiple elements revealed the interface area of the aged anode was rich in Li, F, P, O and C and diffused at least 50 nm into the copper. In comparison, the pristine anode showed a very smooth C/Cu interface. No other elements were detected. For commercial cells, the reactions in the interface area and diffusion of multiple elements into the lattice and grain boundaries were responsible for the embrittlement of the copper current collectors. Finally, permanent cell capacity loss was observed in electrochemical performance of the indented cells.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Wind and structural loads data measured on parabolic trough solar collectors at an operational power plant

Abstract Wind loading is a primary contributor to structural design costs of concentrating solar-thermal power collectors, such as heliostats and parabolic troughs. These structures must resist the mechanical forces generated by turbulent wind, while the reflector surfaces must maintain optimal optical performance. Studying wind-driven loads at a full-scale, operational concentrating solar-thermal power plant provides insights into the wind impact on the solar collector field beyond the capabilities of wind tunnel tests or state-of-the-art simulations. We conducted comprehensive field measurements of the atmospheric turbulent wind conditions and the resulting structural wind loads on parabolic troughs at the Nevada Solar One plant over a two-year period. The measurement setup included meteorological masts and structural load sensors on four trough rows. Additionally, a lidar scanned the horizontal plane above the trough field. In this study, we describe the high-resolution dataset characterizing the complex flow field and resulting structural loads. This first-of-its-kind dataset will enhance the understanding of wind loading on collector structures and will help in designing the next-generation solar collectors and photovoltaic trackers.

14 SOLAR ENERGY↗

DOE OSTI2022

Collection of Aerosol Particles in a Single-Stage, High Gradient Magnetic Collector

The collection of aerosol particles that have magnetic components such as actinides, Co/Ni/Fe, brass, and alloys are of interest in the nuclear industry and for regulatory applications. The collection of these particles is important for monitoring and a number of collection approaches have been developed based on separations mechanisms including size, mass, electrical or thermal properties. In this work, we present the performance of a single-stage, high gradient magnetic collector with a nickel foam matrix for removing airborne magnetic particles. The collection efficiencies for two different particle size regimes and compositions (NaCl and Fe 3 O 4 below 200 nm and SiO 2 and Fe 3 O 4 at 1-2 μm) were measured to assess the performance of the magnetic collector. The high gradient magnetic collector did not remove nanosized magnetic Fe 3 O 4 particles any more effectively than non-magnetic NaCl particles. However, in the larger size range, the collector more efficiently removed Fe 3 O 4 particles compared to SiO 2 with a collection efficiency of 99% compared to 84% for SiO 2 . The removal mechanism could be attributed to both filtration and the high gradient magnetic field.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Loop Thermosyphon Enhanced Solar Collector

A two-phase loop thermosyphon solar collector was developed to transfer thermal energy efficiently and passively from a concentrated solar collector to a thermal desalination process. The two-phase flow in the loop thermosyphon is driven by a difference in gravitational pressure head between the liquid return line and the two-phase riser located between the evaporator and condenser. A numerical model incorporating mass, energy, and pressure drop balances was developed to predict system performance and use as a design tool. Three iterations of loop thermosyphon solar collectors were designed, fabricated, and tested to validate the numerical analysis and demonstrate system integration. Additionally, a novel solar receiver design was evaluated based on volumetric absorption of the concentrated sunlight by an optically absorptive two-phase working fluid. Life tests were performed to evaluate the working fluid thermal stability and resistance to ultraviolet degradation. A glass receiver tube and associated glass-to-metal junctions were developed. Finally, a full-scale loop thermosyphon was integrated with a parabolic trough solar collector and tested on-sun.

14 SOLAR ENERGY↗

NASA NTRS1973

Flat-plate collector performance evaluation. The case for a solar simulation approach

A method is proposed for determining the performance of flat-plate solar collector using a simulated sun. Collector test variables that will help establish the basis for the indoor test facility at the Lewis Research Center are discussed. The use of the indoor testing should permit a standard test for the convenient and accurate determination of collector performance. Preliminary test results are reported as an example of the type of collector performance data to be expected from the simulation approach.

Simon, F. F.↗

NASA NTRS1974

Flat plate collector performance determined experimentally with a solar simulator

The NASA is constructing a new office building at Langley Research Center that will utilize solar energy for heating and cooling. A collector technology program being conducted at Lewis will provide the basis for selecting collectors for use at Langley. The technology program includes testing collectors in an indoor facility under simulated solar radiation. Tests have been conducted on five collectors to date and performance data are presented herein.

Vernon, R. W.↗

NASA NTRS1974

Flat-plate collector performance determined experimentally with a solar simulator

The NASA is constructing a new office building at Langley Research Center that will utilize solar energy for heating and cooling. A collector technology program is described which includes testing collectors in an indoor facility under simulated solar radiation. Tests have been conducted on five collectors to date and performance data are presented. The collector performance obtained with the solar simulator will be correlated with data obtained by conducting tests outdoors at Lewis.

Vernon, R. W.↗

NASA NTRS1975

Outdoor flat-plate collector performance prediction from solar simulator test data

Solar collector performance data obtained from tests with a simulator was modified for real-life conditions. The data obtained with the simulator was corrected for the variable conditions of ambient temperature, wind, incident angle, flow rate, etc., that are encountered outdoors. Modification of simulator data was accomplished by combining experiment with theory. The technique was demonstrated by application to a spectrally selective and a nonselective type of collector. This kind of modified simulator collector performance data should be valuable in solar systems analysis and for collector performance ranking based on all-day calculated conditions.

Simon, F. F.↗

NASA NTRS1975

Development of flat-plate solar collectors for the heating and cooling of buildings

The relevant design parameters in the fabrication of a solar collector for heating liquids were examined. The objective was to design, fabricate, and test a low-cost, flat-plate solar collector with high collection efficiency, high durability, and requiring little maintenance. Computer-aided math models of the heat transfer processes in the collector assisted in the design. The preferred physical design parameters were determined from a heat transfer standpoint and the absorber panel configuration, the surface treatment of the absorber panel, the type and thickness of insulation, and the number, spacing and material of the covers were defined. Variations of this configuration were identified, prototypes built, and performance tests performed using a solar simulator. Simulated operation of the baseline collector configuration was combined with insolation data for a number of locations and compared with a predicted load to determine the degree of solar utilization.

Ramsey, J. W.↗

NASA NTRS1975

Outdoor flat-plate collector performance prediction from solar simulator test data

This paper describes how collector performance obtained from test data with a simulator can be modified for real-life conditions. The approach taken is to correct the performance data obtained with the simulator for the variable conditions of ambient temperature, wind, incident angle, flow rate, etc., that are encountered in outdoor conditions. Modification of simulator data is accomplished by combining experiment with theory. The technique is demonstrated by application to a spectrally selective and a nonselective type of collector. This kind of modified simulator collector performance data should be valuable in solar systems analyses and for collector performance ranking based on all-day calculated conditions.

Simon, F. F.↗

NASA NTRS1975

Silicon crystal as a low work function collector

A test vehicle with a low work function collector which can be incorporated in a thermionic converter was constructed from standard vacuum components including an ultrahigh vacuum ion pump. The collector assembly was fabricated by diffusion bonding a (100) oriented silicon single crystal to a molybdenum block. The silicon surface was treated with cesium and oxygen to produce an NEA-type condition and the results were tested by photoemission and work function measurements. An n-type silicon collector was successfully activated to a work function of 1.0 eV, which was verified by photoemission spectral yield measurements. The stability test of an activated surface at elevated temperatures was conducted in the range from room temperature to 619 K, which was slightly lower than the designed collector temperature of 700 K. The work function measurements clearly demonstrated that the behavior of cesium replenishment on the activated Si surface was similar in nature to that of a metallic surface; that is, the loss of cesium by thermal desorption could be compensated by maintaining an adequate vapor pressure of cesium.

Chang, K. H.↗

NASA NTRS1975

An analysis for designing solar concentrator-collector configurations

An analysis for predicting the heat flux distribution on collectors in the focal region of solar concentrators has been formulated. The analysis is rather general and can consider limb darkening effects, collector placement errors, concentrator optical errors, and concentrator pointing errors. By coupling finite differencing techniques and heating requirements to this analysis, it can also be used to design concentrators that give prescribed heating on the collector surface. Illustrative results are presented. It is concluded that the concentrator and collector should be designed as a unit and that concentrator configurations that are more desirable than the paraboloid and cylindrical parabola can be designed.

Mcdermit, J. H.↗

NASA NTRS1976

Experimental performance of a small size two stage depressed collector for a 4.8-9.6 GHz high performance TWT

Three simple small size two stage depressed collectors were designed and experimentally evaluated in conjunction with a 330 to 520 watt CW, 4.8 to 9.6 GHz traveling wave tube (TWT). Each of the three designs produced a minimum collector efficiency of 80.0 percent considering saturated TWT operation at the maximum of output frequency and at band edges. The highest minimum collector efficiency produced was 80.5 percent with a two stage depressed collector of 4.8 cm diameter by 7 cm high internal dimensions.

Ramins, P.↗